Weil McLain PFG 6 User Manual

EGH-85 & 95  
PFG-6 & 7  
Series 4  
Series 6 & 7  
Control Supplement  
Standing Pilot Boilers  
Controls must only be installed by a Weil-McLain distributor or other  
qualified installer/service technician in accordance with this Supplement and  
all applicable codes and requirements of the authority having jurisdiction.  
Read this Control Supplement completely before beginning the installation.  
If the information in this Supplement is not followed exactly, a fire, explosion,  
carbon monoxide emission or other hazardous conditions can result, causing  
severe personal injury, death or substantial property damage.  
Part Number 550-110-031/0605  
Control Supplement — Standing Pilot Boilers  
Table of contents  
Hazard definitions and Note to the installer .................................................................................... 2  
Control installation — EGH-85 & 95 water boilers........................................................................ 4-5  
Control installation — PFG-6 & 7 water boilers............................................................................ 6-7  
Control installation — EGH-85 & 95 steam boilers with probe-type LWCO................................ 8-9  
Control installation — EGH-85 & 95 steam boilers with float-type LWCO .............................. 10-11  
Checkout procedure ........................................................................................................................11  
Lighting instructions........................................................................................................................12  
Troubleshooting ......................................................................................................................... 13-15  
Parts .................................................................................................................................................16  
Part Number 550-110-031/0605  
3
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7  
Control installation — EGH-85 & 95 water boilers  
Part Number 550-110-031/0605  
4
Control Supplement — Standing Pilot Boilers  
Control installation — EGH-85 & 95 water boilers  
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work  
on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage.  
1. Mount and wire controls per wiring diagram, page  
Figure 1  
4, and Figure 1.  
a. Attach junction box inside left jacket panel with  
#8-32 x ½" machine screws and green ground  
nuts provided.  
b. Install transformer with plug-in relay receptacle  
and relay. In Canada, use chain and hook strain  
relief.  
c. Operating and limit circuit wiring must be 18  
gauge or heavier (as supplied with the boiler).  
2. Bring supply wiring to boiler. Must be 14 gauge or  
heavier.  
Part Number 550-110-031/0605  
5
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7  
Control installation — PFG-6 & 7 water boilers  
Part Number 550-110-031/0605  
6
Control Supplement — Standing Pilot Boilers  
Control installation — PFG-6 & 7 water boilers  
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work  
on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage.  
1. Mount and wire controls per wiring diagram, page  
Figure 2  
6, and Figure 2.  
2. Operating and limit circuit wiring must be 18 gauge  
or heavier (as supplied with the boiler).  
3. Bring supply wiring to boiler. Must be 14 gauge or  
heavier.  
Part Number 550-110-031/0605  
7
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7  
Control installation — EGH-85 & 95 steam boilers  
Part Number 550-110-031/0605  
8
Control Supplement — Standing Pilot Boilers  
with probe-type low water cutoff  
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work  
on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage.  
1. Mount and wire controls per wiring diagram, page  
Figure 3  
8, and Figure 3.  
a. Attach junction box inside left jacket panel with  
#8-32 x ½" machine screws and green ground  
nuts provided.  
b. Install transformer with plug-in relay receptacle  
and relay. In Canada, use chain and hook strain  
relief.  
c. Operating and limit circuit wiring must be 18  
gauge or heavier.  
2. Bring supply wiring to boiler. Must be 14 gauge or  
heavier.  
Part Number 550-110-031/0605  
9
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7  
Control installation — EGH-85 & 95 steam boilers  
Part Number 550-110-031/0605  
10  
Control Supplement — Standing Pilot Boilers  
with float-type low water cutoff  
For your safety, turn off electrical power supply and turn off external gas supply valve before attempting to work  
on the boiler. Failure to comply can cause severe personal injury, death or substantial property damage.  
1. Mount and wire controls per wiring diagram, page  
Figure 4  
10, and Figure 4.  
a. Attach junction box inside left jacket panel with  
#8-32 x ½" machine screws and green ground  
nuts provided.  
b. Install transformer with plug-in relay receptacle  
and relay. In Canada, use chain and hook strain  
relief.  
c. Operating and limit circuit wiring must be 18  
gauge or heavier (as supplied with the boiler).  
2. Bring supply wiring to boiler. Must be 14 gauge or  
heavier.  
Anticipator settings  
Water — 0.40 amps, single zone systems only. For multiple zones using zone  
valves or circulators, refer to component manufacturer’s instructions for  
application, wiring and thermostat heat anticipator setting.  
Steam — 0.20 amps.  
Checkout procedure  
1. Follow all instructions in the boiler manual, including the Checkout procedure, before proceeding.  
2. See page 12 forLighting instructions. Raise room thermostat to call for heat.  
3. Gas valve will open and main burners will ignite.  
4. Lower thermostat setting. Main burner flames will go out.  
5. Repeat steps 1 through 3 several times to verify operation.  
6. Return thermostat to normal setting.  
Part Number 550-110-031/0605  
11  
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7  
Lighting instructions — Robertshaw 7000ERHC  
FOR YOUR SAFETY READ BEFORE LIGHTING  
If you do not follow these instructions exactly, a fire or explosion may result  
causing property damage, personal injury or loss of life.  
A. This appliance has a pilot, which must be lighted C. Use only your hand to depress or turn the gas control knob. Never use  
by hand. When lighting the pilot, follow these  
instructions exactly.  
tools. If the selector arm will not depress or move by hand, don't try to  
repair it, call a qualified service technician. Force or attempted repair  
may result in a fire or explosion.  
B. Before LIGHTING, smell all around the appliance  
area for gas. Be sure to smell next to the floor because D. Do not use this appliance if any part has been under water.Immediately  
some gas is heavier than air and will settle on the  
floor. See below.  
call a qualified service technician to inspect the appliance and to replace  
any part of the control system and any gas control, which has been  
under water.  
WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Immediately call your gas supplier from a neighbor’s phone.  
Follow the gas supplier’s instructions.  
Do not touch any electric switch; do not use any phone in  
your building.  
If you cannot reach your gas supplier,call the fire department.  
LIGHTING INSTRUCTIONS  
1. Stop! Read the safety information above on this label.  
2. Set the thermostat to lowest setting.  
3. Turn off all electrical power to the appliance.  
8. Turn gas control knob counterclockwise  
to PILOT.  
9. Depress gas control knob and hold. Immediately light the  
pilot with a match. Continue to hold gas control knob in for  
about one (1) minute after the pilot is lit.  
4. Depress gas control knob slightly and turn clockwise  
If pilot can be lit without depressing gas control knob,  
to OFF.  
turn gas knob clockwise  
technician or gas supplier.  
to OFFand call your service  
10. Release gas control knob. Pilot should remain lit. If pilot goes  
out, repeat steps 4 through 10.  
If gas control knob stays depressed after release, stop and  
immediately call your service technician or gas supplier.  
If the pilot will not stay lit after several tries, turn the gas  
control knob clockwise  
to OFF and call your service  
Note: Gas control knob cannot be turned to OFF unless  
knob is depressed slightly. Do not force.  
technician or gas supplier.  
11. Replace access panel.  
5. Wait five (5) minutes to clear out any gas. Then smell for  
gas, including near the floor.If you smell gas, STOP!Follow  
"B" in the safety information above. If you don't smell gas,  
go to the next step.  
12. Turn gas control knob counterclockwise  
13. Turn on all electric power to the appliance.  
14. Set thermostat to desired setting.  
15. Replace front panel.  
to ON.  
6. Remove access panel located above burners.  
7. Find pilot — follow metal tube from gas  
control. The pilot is between two burners  
behind the access panel.  
TO TURN OFF GAS TO THE APPLIANCE  
1. Set the thermostat to lowest setting.  
2. Turn off all electric power to the appliance if service is to be  
performed.  
4. Depress gas control knob slightly and turn clockwise  
to OFF.  
5. Replace front panel.  
3. Remove front panel.  
Part Number 550-110-031/0605  
12  
Control Supplement — Standing Pilot Boilers  
Troubleshooting  
have checked the thermopile per step 1 above,  
replace the thermopile lead wire assembly.  
f. If reading on TOP thermopile lead wire is around  
400 millivolts, move the multimeter alligator clip  
to the BOTTOM thermopile lead wire terminal  
and check multimeter reading.  
Verify proper operation after servicing  
Never jumper (bypass) any device except for momentary  
testing as outlined in troubleshooting chart below.  
Substantial property damage and/or severe personal  
injury could occur.  
g. If multimeter does not read around 400 millivolts,  
check wiring connections and wire integrity to  
the limit controls.  
h. Check voltage at each limit terminal to make sure  
limit is closed. Correct pressure or temperature  
condition causing any limit to be open. Replace  
limit if necessary.  
Burner access panel must be in position during boiler  
operation to prevent momentary flame rollout on  
ignition of main flame. Severe personal injury or  
substantial property damage will result.  
Label all wires prior to disconnection when servicing  
controls. Wiring errors can cause improper and  
dangerous operation leading to severe personal injury,  
death or substantial property damage.  
Figure 5  
Before troubleshooting:  
1. Have a voltmeter that can check 120VAC, 24VAC, and a continuity tester.  
2. Check for 120VAC (minimum 102 to maximum 132) to boiler.  
3. Be sure pilot is lit. SeeLighting instructionson page 12 for details.  
4. Make sure thermostat is calling for heat and contacts (including  
appropriate zone controls) are closed. Check for 24VAC between  
thermostat wire nuts and ground.  
Pilot does not stay lit —  
Troubleshooting thermopile and high  
limit control circuit  
1. Checking thermopile open system (Figure 5):  
a. Use an electronic multimeter, with leads fitted with alligator clips. Set  
meter scale to DC Millivolts.  
b. Unscrew thermopile fitting from gas valve.  
c. Attach one meter lead to the end of the thermopile gas valve fitting.  
d. Attach other meter lead to thermopile lead (copper surface).  
Figure 6  
e. Follow Lighting Instruction label on boiler (also found in Control  
Supplement or User’s Information manual) to light the pilot burner  
only and hold the pilot flame manually.(DO NOT light main burner.)  
f. Check the reading on the multimeter. The reading should be around  
700 millivolts.  
g. If multimeter reading is significantly less than above, replace the  
thermopile.  
2. Checking thermopile circuit closed system (Figure 6):  
a. Use an electronic multimeter, with leads fitted with alligator clips. Set  
meter scale to DC Millivolts.  
b. Loosen the insulated terminal on the TOP thermopile lead wire  
enough to allow clipping a multimeter alligator clip to the spade  
terminal.  
c. Attach the other multimeter lead to the thermopile lead.  
d. Check the reading on the multimeter. The reading should be around  
400 millivolts.  
e. If reading is significantly less than 400 millivolts, check tightness of  
lead wire assembly in gas valve. If the connections are secure and you  
Part Number 550-110-031/0605  
13  
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7  
Troubleshooting continued  
Chart 1:  
Boiler will not fire — water boilers without tankless  
Is damper harness securely plugged in at both ends?  
No Yes  
Secure connections.  
Check for loose wire connections or bad relay on  
transformer.  
Is 24VAC present across transformer terminals C & Y?  
No Yes  
Check for open thermostat, LWCO, high limit, spill switch or  
rollout thermal fuse element contacts or check for loose  
wire connections.  
Is 24VAC present across transformer terminal C and yellow  
wire on vent damper connector?  
No  
Yes  
If LWCO, spill switch or rollout thermal fuse  
element contacts are open, determine cause  
and correct condition. Failure to do so will  
cause severe personal injury, death or  
substantial property damage.  
Is vent damper rotated open?  
No  
Yes  
Check/repair out of round stack section. Does vent damper  
rotate open?  
Is 24VAC present across gas valve terminals?  
No  
Yes  
No  
Yes  
Replace actuator.  
Retest.  
Is main flame on now?  
No  
Yes  
Open thermostat contacts for 30 seconds. Vent damper will  
rotate to closed position. Close thermostat contacts. Vent  
damper will rotate to open position. Is 24VAC present  
across gas valve terminals?  
Retest  
Is gas valve cock turned to ON position?  
No  
Yes  
No  
Yes  
Check continuity of each wire in damper harness. Does  
continuity exist for each wire? See Table below.  
Turn gas valve cock to  
ON position. Retest.  
Replace gas valve.  
Retest  
No  
Yes  
Remove damper harness from  
damper harness plug.  
TEMPORARILY install jumper  
Replace damper  
wiring harness.  
Retest.  
between terminal 2 and  
terminal 5 on damper plug in  
boiler wiring harness. See  
figure, right. Does boiler fire?  
No  
Yes  
Replace gas valve.  
Retest.  
Replace damper  
actuator. Retest.  
Part Number 550-110-031/0605  
14  
Control Supplement — Standing Pilot Boilers  
Troubleshooting continued  
Chart 2:  
Boiler will not fire — water boilers with tankless  
Is damper harness securely plugged in at both ends?  
No Yes  
Secure connections.  
Is 24VAC present across combination control terminals V2  
Check for loose wire connections or bad combination  
control.  
& Z?  
No  
Yes  
Check for open thermostat, LWCO, high limit, spill switch or  
rollout thermal fuse element contacts or check for loose  
wire connections.  
Is 24VAC present across transformer terminal V2 and  
yellow wire on vent damper connector?  
No  
Yes  
If LWCO, spill switch or rollout thermal fuse  
element contacts are open, determine cause  
and correct condition. Failure to do so will  
cause severe personal injury, death or  
substantial property damage.  
Is vent damper rotated open?  
No  
Yes  
Check/repair out of round stack section. Does vent damper  
rotate open?  
Is 24VAC present across gas valve terminals?  
No  
Yes  
No  
Yes  
Replace actuator.  
Retest.  
Is main flame on now?  
No  
Yes  
Open thermostat contacts for 30 seconds. Vent damper will  
rotate to closed position. Close thermostat contacts. Vent  
damper will rotate to open position. Is 24VAC present  
across gas valve terminals?  
Retest  
Is gas valve cock turned to ON position?  
No  
Yes  
No  
Yes  
Check continuity of each wire in damper harness. Does  
continuity exist for each wire? See Table below.  
Turn gas valve cock to  
ON position. Retest.  
Replace gas valve.  
Retest  
No  
Yes  
Remove damper harness from  
damper harness plug.  
TEMPORARILY install jumper  
Replace damper  
wiring harness.  
Retest.  
between terminal 2 and  
terminal 5 on damper plug in  
boiler wiring harness. See  
figure, right. Does boiler fire?  
No  
Yes  
Replace gas valve.  
Retest.  
Replace damper  
actuator. Retest.  
Part Number 550-110-031/0605  
15  
EGH-85 & 95 Series 4 and PFG-6 & 7 Series 6 & 7  
Parts  
Part Number 550-110-031/0605  
16  

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